Composite roof and wall system -- three in one -- fireproof, insulation, and waterproofing

ABSTRACT

A composite roof and wall system, three-in-one: fireproof, insulation and waterproofing, which combines fireproof, waterproofing and insulation into one system comprising expanded polystyrene (EPS) foam insulation board; tough waterproofing membrane applied onto the board surface; polyester woven mesh, the reinforcement medium laid over tough waterproof surface; covered by the tough cover, the system&#39;s protective part applied onto the mesh. This system can be directly applied onto any existing roof and wall substrate; or pre-constructed into boards, shingles and tiles using tough water proof material to adhere to the existing roof or wall substrate. This system is nail free to avoid leaking problems, survives physical and weather damages. Pigment can be either mixed with the tough cover or applied onto the surface of the cover. It provides an environmentally safe, lightweight, comparatively inexpensive, energy saving, form flexible and long lasting roof and wall systems, which conserve natural resources.

REFERENCES CITED [REFERENCED BY]

U.S. Patent Documents

-   U.S. Pat. No. 4,712,349 December, 1987 Riley; Elizabeth; Petersen;    Wayne E.-   U.S. Pat. No. 4,965,977 October, 1990 White; Daniel R.-   U.S. Pat. No. 5,215,805 June, 1993 Pavia, Jr.; Alfred-   U.S. Pat. No. 5,251,416 October, 1993 White; Daniel R.-   U.S. Pat. No. 5,735,092 April, 1998 Clayton; Thomas M.; Letts; John    B.-   U.S. Pat. No. 5,787,668 August, 1998 Carkner; Philip M.; Corley;    Todd L.; Dudley; Hubert T.; Kersey; Timothy L.-   U.S. Pat. No. 5,822,943 October, 1998 Frankoski; Stanley P.; Jolitz;    Randal J.-   U.S. Pat. No. 6,044,604 April, 2000 Clayton; Thomas M.; Letts; John    B.-   U.S. Pat. No. 6,110,846 August, 2000 Brzozowski; Kenneth J.;    Chernotowich; Ken-   U.S. Pat. No. 6,177,024 January, 2001 Sandoval; Christopher Paul;    Bauer; Mary Margaret Georgene; DePorter; Craig Donald-   U.S. Pat. No. 6,256,957 July, 2001 Kelly; Thomas L.-   U.S. Pat. No. 6,398,976 June, 2002 Sandoval; Christopher Paul;    Bauer; Mary Margaret Georgene-   U.S. Pat. No. 6,418,687 July, 2002 Cox; Stanley Alfred

TECHNICAL FIELD

This invention relates to the art of roofing and wall systems, and moreparticularly to the application of fireproof, insulation and waterproofthree-in-one roof and wall protective system.

BACKGROUND OF THE INVENTION

Waterproofing has been one of the main concerns and improvementobjections in roofing and building development and so inventions havetaken place all the time. However, serious problems still remain such asleaking, roofing and other related materials are too heavy, or energycostly, or not environmentally conscious, and or economically costly.Some attempts have been made to solve one or some of these problems.Examples to see are: U.S. Pat. Nos. 4,965,977; 5,215,805; 5,735,092;6,044,604; 6,177,024; 6,398,976 and 6,418,687.

U.S. Pat. No. 4,965,977 describes a panelized roof system comprising afoam insulation board with a protective rubber-modifiedbitumen-saturated synthetic fiber mat bonded to the foam board usingrubber-modified bitumen-saturated synthetic fiber strips applied withhot-mopped asphalt to render waterproof.

U.S. Pat. No. 5,215,805 describes a construction panel comprising aclosed cell, expandable foam material having a first surface with twocoatings to enhance fire resistance abrasion resistance and a secondsurface to connect the panel to underlying structure. This constructionpanel of cellular structural foam is objected to be a replacement forceramic and /or cast concrete roofing tiles.

U.S. Pat. No. 5,251,416 describes an insulated panelized roofing systemcomprising a foam insulation board with synthetic fiber mat and a rubbersheet bonded to the top surface completed with a plurality of fastenerspenetrates the sides of the panels and rendered waterproof by aplurality of synthetic fiber reinforced rubber strips applied withadhesive or adhesive tape to the panels' joints.

U.S. Pat. No. 6,044,604 describes composite roofing recovery boardshaving improved dimensional stability and related methods comprising afoam board with a facer reinforced with a group of materials andcomprising a sheet consisting of reinforced polymer and cellulosicmaterials reinforced with a material selected from glass strands, glassfibers and mixtures thereof and gypsum board applied to the oppositemajor surface of the foam core.

U.S. Pat. No. 6,398,976 describes a single ply membrane roofing systemincluding a single ply roofing membrane adhered to the major surface ofan insulation board coated with a latex coating comprising clay, sodiumsilicate and latex.

U.S. Pat. No. 6,418,687 describes an insulated roofing system comprisinga closed sell foamed in place insulation applied over the roof deck orexisting substrate. The preferred foamed in place insulation is aurethane foam.

All these above and some others teach use of panelized or closed cellfoam board roofing systems.

All efforts objected to achieve better roofing systems, which canreplace the conventional type of roofing systems comprising naturalmaterials, which are less and less in supply and so more and moreexpensive to afford and, in most cases, cannot or are difficult tosurvive from weather deteriorations. Improvement and progress have beenmade to make the roofing systems less expensive but more better in termsof weight, energy saving and life span. However, problems of leaks,environmental worries, limited flexibility and some others still existand need to be solved. A complete, flexible, environmentally safe,economically inexpensive and fireproof, insulation and waterproofingthree-in-one composited roof or wall system is needed.

DISCLOSURE OF THE INVENTION

In accordance with the present invention, applicant provides a compositefireproof, insulation and waterproof three-in-one roof and wall systemfor application over a roof or wall substrate comprising a protectivesurfacing material ToughCover, waterproof material ToughWaterproof, asynthetic fiber mat or any other non-combustible woven reinforcementmaterial, named mesh in this invented system and insulation materialexpanded polystyrene (EPS) foam insulation board. The flexibility ofthis system allows the system applied directly onto a roof or wallsurface at a construction site or pre-constructed into boards, shingles,tiles and any other shaped forms and using ToughWaterproof material toadhere them to the existing roof or wall surface at the constructionsite. The flexibility of this invented system also helps to make a heatresistant roof or wall without using EPS foam board to insulate as theprotective cover material ToughCover has the function to prevent notjust fire but resist heat or cold as well. Plus, the elongation abilityof the waterproofing material ToughWaterproof helps out the system tosurvive the damages of thermal changes.

Four Materials Employed and Their Application Methods

1. A rubber like fluid named ToughWaterproof, waterproofing membranematerial applied as an emulsion product. It is odorless, self-adhesiveand brush, spray or roller applied. The characteristics of this coatingare environmentally safe, excellent protection to avoid weather damagesto the surface membranes, easy to apply using spray, brush or roller ata suitable viscosity and comparatively inexpensive. The curedToughWaterproof's characteristics typically are: a. elongation 200-800%;b. durometer (Die-C) 20-80; c. non-permeable; and d. self adhering.

2. A reinforcement medium, constructed of polyester or other type ofnon-combustible, mold and mildew resistant fibers, which is in wovenmesh form and, when it is embedded into a film of elastomeric coating,shall become totally adhered and wrinkle free. This medium is strongenough to hold the lightweight concrete like covering material,ToughCover in place, and it is placed between ToughWaterproof andToughCover. The mesh plays the role of reinforcement supporting theattachment of ToughCover to ToughWaterproof to make the system strongand long lasting.

3. ToughCover is the protective surface of the three-in-one compositeroof and wall system. It is mainly a composition of cement, clay,perlite, sand, etc. At job or construction sites, ToughCover is mixedwith water to make it into paste form, which is sprayed or rolled ontothe mesh, which is overlaid on the ToughWaterproof, the waterproofingpart of the three-in-one system. This protective surfacing may beapplied from one-sixteenth ( 1/16th) inch to one (1) inch thick, and itis sufficiently strong to support normal pedestrian traffic. ThisToughCover coating resists fire; weather damages including ultraviolet(UV) and ozone degradation, winds' uplift, rain, hail, and other droppedobjects' ruin and provides insulation values by resisting heat buildupand/or absorption.

This three-in-one composite system fits both roof and wall systems andboth the materials used and the steps involved for using them are thesame.

4. Expanded polystyrene (EPS) foam insulation board is used to insulatethis three-in-one roof and wall system, if it is desired for an existingroof or wall, or it is used as the base for pre-constructing said systeminto tile or shingle and flat or shaped board forms. While EPS foamboard is required to be used as the base of the pre-constructed systemin shingle, or tile or board forms, it is optional when dealing withflat or slightly sloped roofs or walls when insulation is not needed orwanted. EPS foam board gives the three-in-one roof or wall system asurplus of insulation. The composite roof and wall system is simply doneas following:

For the non-sloped flat roof, the EPS foam board is pre-cut preciselyaccording to the slop degree needed to suit water draining needs of theexisting roof. Then, the pre-cut EPS foam board is glued on the roofsurface using ToughWaterproof as the glue or adhesive material.

When this fourth material-EPS foam board-is used, the water-proofing ofthis three-in-one roof and wall system takes place after the EPS foamboard is placed on the surface of the existing roof or wall, it(ToughWaterproof) is sprayed on or rolled on the surface of the EPS foamboard. And, the reinforcement medium material “mesh” is laid on theToughWaterproof membrane applied over the EPS foam board. The last stepis to spray or roll on the protective material ToughCover onto thereinforcement medium material mesh applied on the EPS foam board.

To make this three-in-one composite roof and wall system tiles orshingles or wallboards, the first step is to spray or rollToughWaterproof onto the pre-cut EPS foam board and place the pre-cutmesh onto the fresh and wet surface of the ToughWaterproof applied onthe surface of the EPS foam board. Then, ToughCover pre-mixed paste isbrushed or rolled onto the mesh placed on the Tough-Waterproof. Afterthe tiles or shingles or the wallboards are made, they can either bedried naturally or put into a pre-heated oven to dry to the cureddegree. The ToughWaterproof is used to glue these tiles or shingles orwallboard onto the existing roof, and no nails are needed or allowed.

These tiles or shingles or wallboards are shaped to overlap or interlockwith each other and the waterproofing material ToughWaterproof isapplied between the EPS foam board as the base and ToughCover as thesurface of the tile or shingle or the wallboards. A waterproofingmembrane on the surface of the existing roofs or walls is unnecessary,however, as ToughWaterproof material is used to adhere thepre-constructed shingles, tiles, or boards to the existing roof or wallsubstrate. So, the ToughWaterproof is well rolled or brushed or sprayedonto the existing roof or wall surface to adhere the pre-constructedshingles, or tiles or walls to the existing roof or wall surface; in themeantime it doubles the waterproofing of the roofs or walls.

SUMMARY OF THE INVENTION

The object of this invention is to provide a “Composite Roofing and WallSystem-Three-in-One—Fireproof, Insulation and Waterproof,” which isenergy saving, environmentally safe, weather resistant rendered,economically inexpensive with a longer dependable life span.

In this objected fireproof, insulation and waterproof three-in-onecomposite roofing and wall system, EPS foam insulation board is optionalin the case of applying directly onto the existing roof or wallsubstrate. ToughWaterproof material can be directly applied onto theexisting roof or wall substrate reinforced by non-combustible polyesterwoven mesh and covered by ToughCover, the protective cover material andthe objected three-in-one composite roof or wall system is constructed.However, the EPS foam insulation board is recommended to gain energysaving and to help the waterproofing membrane to last longer.

This invented system is also objected to pre-construct a fireproof,insulation and waterproof three-in-one composite system in shingle, tileor panelized board forms, comprising a pre-cut EPS foam insulation boardin the shape and size desired or wanted, ToughWaterproof applied ontothe EPS foam board surface to get waterproof membrane done, then thereinforcement medium mesh is laid over onto the ToughWaterproofmaterial; and ToughCover, the protective cover material is applied ontothe mesh and the fireproof, insulation and waterproof three-in-onecomposite roof or wall system is constructed in shingle, or tile orpanelized board forms. And, at the job or construction site, they can beeasily adhered to the existing roof or wall substrate usingToughWaterproof as the adhesive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1: This system is installed onto the substrate of existing wood,concrete, metal and many other kinds of roofs or walls.

FIG. 2: This system is installed onto an intermediate rigid foamsubstrate base surface. The rigid foam is installed onto ToughCoverfilled metal deck flutes. However, the foam may also be mechanicallyattached directly to the metal deck. The installed rigid foam insulationbecomes the base for receipt of this system.

FIG. 3: The system is installed onto a previously installed rigid foaminsulation base.

FIG. 4: This system is applied onto single-shaped rigid foam insulationshingle, or tile or flat or shaped board. The completed shingle or tileor board is then installed onto properly sloped roof deck or verticalwall substrates.

FIG. 5 The system is applied onto shingle-shaped rigid foam insulationshingle. The completed shingle is then installed onto properly slopedroof deck or vertical wall substrates.

1. A composite roof and wall system, three-in-one: fireproof, insulationand waterproofing, comprising an expanded polystyrene foam board adheredonto the existing roof deck or wall by using a tough modified bitumenwaterproofing membrane coating as the adhesive to glue onto the existingroof or wall substrate and connected with each other by constructiontape, such as butyl tape, or by using the modified bitumen waterproofingmembrane coating to seal the seams between the foam boards; thewaterproofing membrane is fully brushed, rolled or sprayed over the foamboards with a mesh material placed over said tough waterproof membranecoating for reinforcement; and a composition of cement, clay, perlite,sand, etc. to form a tough cover is placed over the mesh by brushing orrolling or spraying onto said system to protect if from fire, physicaland weather damages.
 2. A composite roof and wall system, three-in-one:fireproof, insulation and waterproofing, comprising according to claim 1wherein said expanded polystyrene foam board must be rigid andnon-flammable and is between 2 inches to 8 inches in thickness, placedon the surface of said tough waterproof membrane coating freshly andwell brushed or rolled or sprayed onto the surface of the existing roofsor walls as the first waterproofing coating.
 3. A composite roof andwall system, three-in-one: fireproof, insulation and waterproofing,comprising, according to claim 1 wherein said tough waterproofingmaterial is made of modified asphalt emulsion with natural and syntheticresins, applying two to three times onto the roof or wall surface using0.125 to 0.25 gallon per square yard.
 4. A composite roof and wallsystem, three-in-one: fireproof, insulation and waterproofing, accordingto claim 1 wherein said reinforcement medium mesh is woven polyestertype of mold and mildew free and non-flammable or non-combustible havinga weight between 0.01 to 1 ounces per square yard depending on theneeds.
 5. A composite roof and wall system, three-in-one: fireproof,insulation and waterproofing, according to claim 1 wherein saidlightweight tough coat comprising cement, clay, silicate (perlite),sand, etc., mixed with water to make it into paste form at job site andhaving a thickness of said paste between 0.125 inches to 0.75 inches,using said lightweight tough coat mixture between 3 to 10 pounds persquare yard and allowing twenty days or so to be fully cured.
 6. Acomposite roof and wall system, three-in-one: fireproof, insulation andwaterproofing, according to claim 1, claim 2, claim 3, claim 4 and claim5, said tough waterproofing membrane coating having excellent elongationability and tough cover featuring fire and ultra violet related weatherresistance, said foam board insulation being not necessary needed forthe flat or inclined roofs or walls.
 7. A composite roof and wallsystem, three-in-one: fireproof, insulation and waterproofing, accordingto claims 1 through 5, said system also being pre-constructed into theforms of boards, shingles or tiles.
 8. A composite roof and wall system,three-in-one: fireproof, insulation and waterproofing, according toclaim 1, claim 2 and claim 6, said expanded polystyrene foam boards usedas the base of said boards, shingles or tiles.
 9. A composite roof andwall system, three-in-one: fireproof, insulation and waterproofing,according to claim 1, claim 3 and claim 7, tough waterproofing coatingis applied to the surface of said board by brushing, rolling or sprayingonto the surface of said board, playing the waterproofing role of saidsystem.
 10. A composite roof and wall system, three-in-one: fireproof,insulation and waterproofing, according to claim 1, claim 4 and claim 8,said mesh material is laid over the surface of the tough waterproofcoating when freshly applied.
 11. A composite roof and wall system,three-in-one: fireproof, insulation and waterproofing, according to allthe above claims, said tough cover, a protective lightweight concretecoating material being brushed, or rolled or sprayed onto said mesh laidover the surface of tough waterproof membrane coating to avoid anyphysical or weather damages, said system of said boards, shingles andtiles being formed after a natural curing period of 20 days at 10.0 orhigher centigrade degrees.
 12. A composite roof and wall system,three-in-one: fireproof, insulation and waterproofing, according toclaim 11, said system of pre-constructed boards, shingles and tiles laidover the existing roofs or walls, using a tough waterproof membranecoating to adhere and said tough waterproofing coating being wellapplied onto the surface of the existing roofs or walls to double thewaterproofing of said composite roof and wall system, whereby astructure will have strong three-in-one: fireproof, insulation andwaterproofing, system.